What does this research mean for the field?

In friction stir welding of dissimilar aluminium alloys AA6061-T6 and AA7075-T6, tool pin profile is the dominant factor determining ultimate tensile strength, with optimal parameters achieving a joint efficiency of 70.3%. Novelty: ClaimNovelty.INCREMENTAL. Consensus alignment: ConsensusAlignment.NEUTRAL.

What question did this study set out to answer?

To optimize friction stir welding parameters for joining dissimilar aluminum alloys AA6061-T6 and AA7075-T6 and evaluate their effects on mechanical properties and microstructure.

August 14, 2026Open Access

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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Authors

PBP. P. Bhise

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Implication

Experimental study optimizes friction stir welding parameters in dissimilar aluminum alloys, demonstrating enhanced tensile strength and microstructural refinement.

Key Points

To optimize friction stir welding parameters for joining dissimilar aluminum alloys AA6061-T6 and AA7075-T6 and evaluate their effects on mechanical properties and microstructure.
Utilized a Taguchi L16 orthogonal array to test four parameters: tool rotation speed (600–1400 rpm), welding feed rate (40–60 mm/min), tool pin profile (cylindrical, tapered, threaded taper), and axial force (4–6 kN).
Evaluated ultimate tensile strength, Vickers microhardness, and microstructure across sixteen runs, analyzing results via Signal-to-Noise ratio and ANOVA.
Tool pin profile was the most influential parameter for tensile strength (38.4% contribution), followed by rotation speed (26.2%) and feed rate (22.8%).
Optimal parameters (1000 rpm, 60 mm/min, threaded taper pin, 5 kN axial force) yielded an ultimate tensile strength of 218 MPa, 70.3% joint efficiency relative to AA6061-T6, and a peak nugget zone microhardness of 126 HV.
Dynamic recrystallization created a refined equiaxed grain structure in the nugget zone (average grain size 4.2 µm), compared to 28.4 µm in AA6061-T6 and 12.6 µm in AA7075-T6 parent metals.

Cite This Study

P. P. Bhise (2026) studied this question.

synapsesocial.com/papers/6a7ec775b70b84ec8b913d7c https://doi.org/10.5281/zenodo.21902895

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Implication

Experimental study optimizes friction stir welding parameters in dissimilar aluminum alloys, demonstrating enhanced tensile strength and microstructural refinement.

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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Cite This Study

Optimisation of Friction Stir Welding Parameters for Dissimilar Aluminium Alloys AA6061-T6 and AA7075-T6: Effect of Tool Pin Profile, Rotation Speed, and Feed Rate on Joint Strength, Microhardness, and Microstructure

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